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Remove/install differential - AR35.31-P-0520SX

MODEL 216.371 /373, 221.00 /02 /057 /073 /074 /080 /082 /083 /094 /10 /122 /126 /15 /170 /171 /173 /174 /18 /19 

MODEL 221.128 except CODE (Z07) Top protection 

MODEL 216.38/ 39 

Fig 1: Identifying Remove/Install Differential Components
G07643201Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES

25.6.10 Value changed: Self-locking nut, flex disk to rear propeller shaft or rear axle differential M12 see *BA41.10-P-1002-01H 
REMOVINGINSTALLING Remove/install     
NOTES Notes on self-locking nuts and bolts   see AH00.00-N-0001-01A
    NOTES While working on the rear axle care must be taken to ensure that the surface of all aluminum components do not get any scratches, cracks and notches. Otherwise the service life of the of the parts will be reduced.  
1 Move parking brake into the assembly position using STAR DIAGNOSIS    
REFER TO SELF-DIAGNOSTIC SYSTEMS Connect STAR DIAGNOSIS see AD00.00-P-2000-04A
2 Secure vehicle on vehicle lift   see AR00.60-P-0100SX
3 Remove exhaust system from flange connection back Vehicles with gasoline engine see AR49.10-P-7100SX
Vehicles with diesel engine AR49.10-P-7100SXI
4 Detach propeller shaft (106) from joint flange on differential (50)   see AR41.10-P-0050-03SX
IMPORTANTInstallation:  Attach propeller shaft (106) at joint flange to differential (50). see AR41.10-P-0050-04SX
TORQUE SPECIFICATION see *BA41.10-P-1002-01H 
5 Loosen fitting sleeves of flex disk on joint flange of differential (50)   see AR41.10-P-0050-09SX
REFER TO SHOP-MADE TOOLS Drift for loosening fitting sleeves in flex disks. see WF58.50-P-4110-01A
6 Remove right rear axle shaft (37) Vehicles with inserted rear axle shafts (37) see AR35.30-P-0620SX 
7 Unscrew nuts (5) and remove controller unit (A13) from bracket (13h) IMPORTANT Do not disconnect electrical connectors.  
TORQUE SPECIFICATION see *BA42.20-P-1001-01K 
8 Loosen bracket (13h) of controller unit (A13) on front differential mount (51); to do this, remove bolt (13s) TORQUE SPECIFICATION see *BA42.20-P-1004-01K 
9 Support differential (50) with transmission jack and transmission plate and lash down securely    
10 Mark installation position of sleeve (64h) NOTES If the bush (64h) is installed twisted, it will cause a change in articulation angle at the propeller shaft (106) which will in turn cause drivetrain vibrations.  
11 Remove bolt (64b) from rear axle differential mount and remove bolt (64b) with sleeve (64h) TORQUE SPECIFICATION see *BA35.10-P-1004-01M 
12.1 Remove bolts (1) and remove right exhaust rubber mount (2). TORQUE SPECIFICATION Engine 157, 272, 273, 276, 278 see *BA49.10-P-1009-01Z 
TORQUE SPECIFICATION Engine 629 see *BA49.10-P-1006-01AA 
TORQUE SPECIFICATION Engine 642 see *BA49.10-P-1010-01V 
12.2 Detach exhaust rubber mounting (2) from frame floor assembly TORQUE SPECIFICATION Engine 651 see *BA49.10-P-1001-01AJ 
13 Remove left and right bolts (51a) of front center assembly mount (51) TORQUE SPECIFICATION see *BA35.10-P-1003-01M 
14 Lower the differential (50) slightly    
15 Lift out the left rear axle shaft (37) from the rear axle center assembly (50) IMPORTANT Do not fasten an assembly lever to the protection ring (37a). Support assembly lever using, e. g. socket wrench on rear axle differential (50).
IMPORTANT Secure left rear axle shaft (37) against falling down.
IMPORTANTInstallation:  Install new retaining ring (37o) on inner splined profile.		  
16 Lower differential (50) further    
17 Remove bolts (51d) and remove front differential mount (51) from rear axle differential (50) When fitting new rear axle differential (50)  
TORQUE SPECIFICATION see *BA35.10-P-1007-01M 
18 Remove bolts (52s) and adapter (52) from rear axle differential (50) When fitting new rear axle differential (50)  
TORQUE SPECIFICATION see *BA35.10-P-1006-01M 
19 Detach extension bracket from rear axle differential (50) When fitting new rear axle differential (50)  
Refer to "Remove end cover on differential (50)". see AR35.31-P-0554SX 
20 Install in the reverse order    
21 Check oil level in differential (50) and correct if necessary   see AR35.31-P-0520-03SX 
TORQUE SPECIFICATION see *BA35.31-P-1002-02G 
FLUID SPECIFICATION see *BF35.31-P-1001-01S 
Sealant see *BR00.45-Z-1061-01A 
Cleaning spray see *BR00.45-Z-1046-04A 
22 Perform wheel alignment check   see AR40.20-P-0200SX
REAR AXLE CARRIER

Number Designation Model 216 Model 221 except 221.176/179 with rear axle differential 240V
BA35.10-P-1003-01M Self-locking bolt, front crossmember to rear axle carrier Stage 1 Nm 50 50
Stage 2 ∠° 90 90
BA35.10-P-1004-01M Self-locking nut securing rear extension bracket to rear axle carrier Stage 1 Nm 100 100
Stage 2 ∠° 90 90
BA35.10-P-1006-01M Adapter to rear axle differential Stage 1 Nm 110 110
Stage 2 ∠° 90 90
BA35.10-P-1007-01M Adapter to front transverse bridge Stage 1 Nm 50 50
Stage 2 ∠° 90 90
EXHAUST SYSTEM

Number Designation Engine 651 in model 221
BA49.10-P-1001-01AJ Bracket, exhaust rubber mount to body Nm 22
EXHAUST SYSTEM

Number Designation Engine 278 in model 216 Engine 276 in model 221 Engine 278 in model 221
BA49.10-P-1009-01Z Bolt, exhaust rubber mount to rear axle carrier Nm 22 22 22
PROPELLER SHAFT

Number Designation Model 216 Model 221
BA41.10-P-1002-01H Self-locking nut, flex disk to rear propeller shaft or differential M12 Nm 68 68
EXHAUST SYSTEM

Number Designation Engine 157 in model 216/221
BA49.10-P-1009-01Z Bolt, exhaust rubber mount to rear axle carrier Nm 20
PARKING BRAKE

Number Designation Model 216 Model 221
BA42.20-P-1001-01K Nut, electric parking brake controller unit to bracket Nm 7 7
BA42.20-P-1004-01K Bolt, bracket of electric parking brake control unit to front crossmember Nm 15 15
EXHAUST SYSTEM

Number Designation Engine 272 in model 221 Engine 273 in model 221 Engine 273 in model 216
BA49.10-P-1009-01Z Bolt, exhaust rubber mount to rear axle carrier Nm 20 20 20
EXHAUST SYSTEM

Number Designation Engine 629
BA49.10-P-1006-01AA Bolt, exhaust rubber mount to rear axle carrier or frame floor assembly Nm 20
EXHAUST SYSTEM

Number Designation Engine 642 in model 221
BA49.10-P-1010-01V Bolt, exhaust rubber mount to rear axle carrier Nm 20
DIFFERENTIAL HOUSING

Number Designation Model 216 Model 221
BA35.31-P-1002-02G Oil filler screw, differential Nm 50 50
DIFFERENTIAL

Number Designation Model 216 Model 221
BF35.31-P-1001-01S Filling capacity Rear axle differential 200FE, 200 mm dia. Liters 1.1 1.1
Rear axle differential 215FE, 215 mm dia. Liters 1.2 1.2
Rear axle differential 240FE, 240 mm dia. Liters 1.6 1.6
Rear axle differential 240V, 240 mm dia. Liters - 1.9
Specifications for service products Sheet see BB00.40-P-0235-07A see BB00.40-P-0235-07A
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1061-01A Sealant, Omnifit 100H (50 g) A 002 989 23 71
BR00.45-Z-1046-04A Loctite 7063 cleaning spray (150 ml) A 001 986 71 71 10
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